CN1805912B - Method of preparing layers of oxides of metallic elements - Google Patents

Method of preparing layers of oxides of metallic elements Download PDF

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CN1805912B
CN1805912B CN200480016763XA CN200480016763A CN1805912B CN 1805912 B CN1805912 B CN 1805912B CN 200480016763X A CN200480016763X A CN 200480016763XA CN 200480016763 A CN200480016763 A CN 200480016763A CN 1805912 B CN1805912 B CN 1805912B
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base material
dispersion
described method
suspension
powder
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CN1805912A (en
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M·戈登
C·拉伯蒂-罗伯特
F·安萨特
P·斯蒂芬斯
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Electricite de France SA
Centre National de la Recherche Scientifique CNRS
Universite Toulouse III Paul Sabatier
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Electricite de France SA
Centre National de la Recherche Scientifique CNRS
Universite Toulouse III Paul Sabatier
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Abstract

The invention relates to a method of preparing a metallic element oxide layer on a substrate. The inventive method comprises the following successive steps consisting in: a) dispersing a metallic element oxide powder in a liquid medium which contains a dispersion solvent and a dispersant, but which does not contain a plasticiser nor a binder, such as to produce a suspension A of the powder in theliquid medium; b) adding a solution of at least one polymer in a solvent to suspension A, such as to produce a suspension B; c) depositing suspension B on the substrate using a dip-coating method, such as to produce a raw layer; d) drying the raw layer obtained in step c; and e) calcining the dried layer obtained in step d.

Description

The preparation method of layers of oxides of metallic elements
The present invention relates to a kind of preparation method of layers of oxides of metallic elements.
Can be commonly defined as technical field of the present invention at base material, particularly metal, ceramic base material or with deposited ceramic layer, the particularly technical field of metallic element thin oxide layer on closely knit or the base material that sintered glass is made.
The present invention is applied to deposit mixed oxide the class for example low thickness negative electrode and the dense dielectric substrate of the zirconium white of doped with yttrium (YSZ) especially in Solid Oxide Fuel Cell (SOFC).
The deposition method of layers of oxides of metallic elements can be divided into two classes: promptly a class is a dry method, and another kind of is wet method.
About dry method, especially can the using plasma method and vacuum sputtering prepare ceramic metal element oxide film.
In plasma method, a kind of powder sputtering is made on its powder refrigerative base material to a kind of by plasma body.The film maximum ga(u)ge that adopts these methods to synthesize is 10 μ m, still, and for the porosity that reduces film also should replenish deposition.Another restraining factors of these methods are to be merely able to use the simple base material of geometrical shape.
These evaporating deposition techniques they all need high performance vacuum system just can deposit the film with good quality of thickness less than 10 μ m.In addition, this high cost technology also is subjected to the restriction of base material geometrical shape.
About wet method, these methods that can low-cost deposition different thickness layers of oxides of metallic elements be the chemical process of carrying out in solution basically, for example sol-gel method and doctor-blade casting process (coulage en bande).
Sol-gel method can be divided three classes: the organic method of metal, alkoxide method and the polymeric method of distinguishing according to colloidal sol character.
A kind of particularly advantageous sol deposition technology, particularly in the polymeric method scope so-called submergence-taking-up technology (English is the dipping technology), this technology can be divided into for four steps roughly: base material is immersed in the colloidal sol, from colloidal sol, take out base material with control speed, so cause this layer deposition, discharge the colloidal sol and the evaporating solvent of base material.
The sol-gel method that particularly adopts submergence-taking-up coating technology to implement can not be prepared the layer of thickness greater than 1 μ m once going on foot.
In fact, the individual layer maximum ga(u)ge that classical sol-gel method obtains generally speaking for 100nm until 250nm, therefore, repeatedly do not deposit in succession and just can not obtain the big oxide skin of thickness.In addition, in order under good condition, to deposit, need carry out repeatedly polishing operation to base material.
One of them main restricting factor of sol-gel method is to adopt this method to be difficult to stringer on a kind of porous substrate.In fact, if these base materials have the open form hole, colloidal sol can infiltrate in the base material hole by wicking action during deposition.At this moment need base material is carried out pre-treatment, for example apply a kind of intermediate film on base material, its base material should be reduced to low temperature, so this thin layer is fixed on the base material.
Under the particular case of the dielectric substrate of fuel cell " SOFC ", the inventor proves, and sol-gel method can not be on closely knit base material, let alone obtains the dense layer that the covering of adequate thickness is not split uniformly on porous substrate, for example the YSZ layer.
In other words, the YSZ layer thickness that obviously adopts sol-gel method to reach is not enough to meet " SOFC " electrolytical technical specifications.In addition, if base material is closely knit, also have same character, then synthetic YSZ layer causes oxide compound in the inhomogeneous crystallization of base material specific site.
Under more such conditions, obviously be difficult to obtain uniform dense layer, even the deposition of carrying out in succession also is like this.At porous substrate, for example under the situation of Ni-YSZ, these problems also can be more serious, and Ni-YSZ is the anode material of effective sale " SOFC ".
Doctor-blade casting process is a kind of thick-layer forming process, and this technology is used in particular for producing the electrolytical main part of " SOFC " types of fuel cells.
This method need be made suspension with ceramic powder in general non-water-bearing media, also may contain many additives, comprising dispersion agent, organic binder bond and softening agent.
The committed step of this method is prepare suspension.This suspension is just as " cream " shape, should be uniformly, also unusual thickness.For the stability that guarantees suspension need be added dispersion agent.In order to be easy to make this suspension deposition, also need to add tackiness agent and softening agent, make its suspension that a kind of force of cohesion and a kind of suitable elasticity be arranged.All these components constitute " mud " that is referred to as flow casting molding.In case prepare this mud, just use the blade that this cream is floating that it is placed on the surface, form a kind of " life " film.
Doctor-blade casting process has many defectives, and character and the dosage of in fact controlling chemical compound lot in the mud are very thorny.As if on the other hand, adopt this method to produce thickness also very difficult less than ten microns ceramic membrane uniformly densely.Yet at fuel cell in particular cases, being reduced to electrolyte thickness less than 10 μ m is very necessary for the working temperature that reduces these batteries.
At last, the very flexible of doctor-blade casting process is because it is difficult to be applied to optional base material with complex geometry of high surface area.
Therefore, also do not have a kind of method can prepare the layers of oxides of metallic elements with variable thickness on the base material of any kind, its thickness can be 1 μ m to tens μ m particularly, for example up to 200 μ m.
Also need a kind of method easy, reliable, with low cost, the step number of this method is limited, can be on closely knit base material, also can prepare the even high-quality layer, film, the settling that do not split with controlled porosity on porous substrate, these base materials can also have very big surface-area and/or can have complicated geometrical shape.
Also need a kind of like this method, it does not need base material, and particularly porous substrate carries out any pretreatment operation, for example puts the preparation property polishing or the deposition of film in order.
Need a kind of method especially, it can be preferably with single and unique step deposition metal oxide layer, and its thickness range is 1-10 μ m; For thin or thick film forming, adopt above-mentioned technology in fact can not reach this thickness range, promptly the thickness of sol-gel method is less than 1 μ m, or the thickness of flow casting molding technology is higher than 10 μ m.
The purpose of this invention is to provide the method for preparing layers of oxides of metallic elements on a kind of base material that on meet especially, requires.
Purpose of the present invention also provides a kind of method for preparing layers of oxides of metallic elements on base material, it does not have art methods, the particularly defective of sol-gel method and doctor-blade casting process, shortcoming, unfavorable and limitation, this method has solved these problems of art methods.
According to the present invention, adopt the method that on a kind of base material, prepares layers of oxides of metallic elements can reach this purpose and other purpose, wherein carry out following sequential step:
A) the metallic element oxide powder is dispersed in the liquid medium that contains dispersion solvent and dispersion agent, described liquid medium is plasticizer-containing neither, do not contain tackiness agent yet, obtain the dispersion A of described metallic element oxide powder in described liquid medium like this;
B) add the solution of at least a polymkeric substance in solvent toward described dispersion A, obtain suspension B like this;
C) adopt submergence-taking-up coating method on base material, to deposit suspension B, obtain giving birth to layer (couchecrue) like this;
D) layer of giving birth to that obtains in the step c) carries out drying;
E) drying layer that obtains in the step d) is calcined.
Method of the present invention has a serial especially particular step of never describing in the prior art.
Method of the present invention has in fact comprised the feature that adopts polymer class colloidal sol submergence-taking-up method and doctor-blade casting process to prepare the oxide skin method simultaneously.
Therefore, to be combined into this fact of the inventive method itself be extremely wonderful to the technical characterictic that will belong to two kinds of fundamental difference methods.
Method of the present invention in fact can determine it is a kind of buffering technique between colloidal sol submergence-taking-up method and doctor-blade casting process.
Method of the present invention adopts a kind of submergence-taking-up coating technology to prepare the settling of these suspension on base material based on prepare suspension then.
The difference of the inventive method and sol-gel method is to utilize the suspension of metal oxide powder in the dispersion solvent, and its solvent itself is added in the polymer sol, rather than is added in a kind of true colloidal sol.Therefore, can apply at porous substrate without difficulty.
Compare with " flow casting molding " method, the suspension that the present invention uses has been broken away from and the difficulty of using softening agent and tackiness agent to be associated with other additive.
To adopt immersion coating (" dipping ") be extremely wonderful in order to carry out suspension deposition, and this method is generally used for the deposition of solution.
The sedimentation that the present invention adopts (adopting the submergence coating) has greater flexibility than doctor-blade casting process, also guarantees at high surface area, for example surface-area 1cm 2To 100cm 2And/or has a settling that excellent quality is arranged on the base material of complex geometric shapes.
Method of the present invention has all advantages of sol-gel method and doctor-blade casting process, and does not have any defective that they have.
Therefore, method of the present invention as sol-gel method, has following advantage:
-on the base material of complicated shape and/or high surface area, can deposit,
After-the calcining, because the polymer unwinds that contains in the deposition suspension, this layer is tightly adhered on the base material;
Yet on the other hand, be not limited by be lower than the micron small thickness and the defective of nonporous substrate.
Similarly, method of the present invention as doctor-blade casting process, has following favourable feature:
Any possibility that can make pulverous metallic element oxide compound of-deposition, as long as the powder of preparation can be dispersed in the solution, method promptly of the present invention can be applied to very a large amount of oxide compounds.
-on porous substrate, carry out sedimentary possibility,
Yet do not utilize softening agent, tackiness agent and other additive, especially be not limited by the defective that thickness is higher than 10 μ m.
After step e) finishes, promptly need not repeat this method, particularly need not repeat the step c) and the d of this method), method of the present invention can prepare some variation in thickness scopes can be very wide, the layer of 1-100 μ m for example, these layers have controlled porosity, and are closely knit or porous substrate is all like this.A special benefit of the inventive method is, the thickness range that it can reach especially is 1-10 μ m, and the technology that adopts usually when thin or thick film moulding can not reach this thickness range, because sol-gel method is merely able to prepare the following layer of 1 μ m, and doctor-blade casting process can only the above layer of deposit thickness 10 μ m.
The quality of the layer of employing the inventive method preparation is splendid, also very even, flawless, and thickness is well-balanced.
In other words, on the base material of closely knit, porous, size is either large or small, geometrical shape is simple or complicated any kind, these layers all have the microstructure of improving very much control.Adopt the film of the inventive method preparation, because its morphological specificity and its character and all be particularly suitable for ionogen in high-temperature fuel cell or the thermal boundary.
Method of the present invention guarantees very accurately to control the microstructure of deposit film: this relates to the porosity that can change in 0-30 volume %, the particle size that can in 50nm to 5 μ m for example, change, and can be at 1m 2/ m 2To 100m 2/ m 2More than in the specific surface area ratio of the base material geometrical shape surface-area that is covered by this settling (the true surface-area of oxide compound with) that changes.
In addition, opposite with prior art, there is no need to adopt polishing or preparatory deposit film that base material is carried out pre-treatment, therefore simplified this method greatly.Method of the present invention is just implemented the simple and reliable step of limited quantity, makes production cost reduce like this.
Generally speaking, make the simple oxide that lamellated oxide compound is selected from transition element and lanthanon, the multiple mixed oxide of these metallic elements, and the mixture of these simple oxides and mixed oxide are selected its oxide compound according to its intended application.
Particularly preferred oxide compound be have cube or the tetragonal system structure contain the yttrium zirconium white.
Generally speaking, the dispersion solvent that uses in step a) is selected from water, ketone, aliphatic alcohol class and composition thereof.
Particularly preferred dispersion solvent is an ethanol methylethylketone azeotropic mixture (ratio by volume: 60-40).
Usually, the metallic element oxide powder content in dispersion A is 1-80 quality %, preferably 20-60 quality %, more preferably 30-50 quality %, 30-40 quality % better.
This metal oxide powder particle size generally is 5nm to 5 μ m, preferably 100-300nm, 50nm-300nm better.Its dimension definitions is the overall dimension of this particulate.These particulates can have Any shape, but preferably this powder particle have usually sphere or with the similar shape of sphere.At this moment, their size is determined with its spherical diameter.
Generally speaking, this dispersion agent is selected from ion and nonionogenic tenside, for example phosphoric acid ester.
Particularly preferred dispersion agent is The trade(brand)name that SA company sells
Figure G200480016763XD00062
The P312 phosphoric acid ester.
Usually, the mass content of dispersion agent is the metallic element oxide compound dry powder 0.1-10 quality % to add, preferably 2-3% in dispersion A.
Generally speaking, the polymkeric substance in the solution of step b) is selected from polymkeric substance or the ester with long carbochain.Preferably, this polymkeric substance is selected from poly-(aliphatic ester).
A kind of particularly preferred polymkeric substance is for example in the acetic acid medium, to react resulting polymkeric substance by vulkacit H and Acetyl Acetone at acidic medium.
In the present invention, the measuring method of polymer content and polymer chain length is a viscosity of measuring this solution in the solution of step b).
The viscosity of this solution can be 5mPa.s-1000mPa.s, preferably 20mPa.s-100mPa.s.
Generally speaking, in step b), according to mass ratio (r with polymers soln quality and dispersion A quality m) 0.01-3,0.1-0.6 preferably, more preferably the ratio represented of 0.1-0.5 is added this polymers soln among the dispersion A to.
In this manual, term dispersion suspension liquid is represented " dried powder " dispersion in moisture or organic solvent.It is illustrated in realizes in the liquid medium powder " separation " is become single particulate: do not have aggregate, agglomerate or throw out.
In addition, in this manual, use the term aggregate to represent a kind of single particulate " bag " (single crystal has the common crystal plane) of highly dense, and the term agglomerate is represented a kind of more low-density bag (a little less than the single particulate connection, therefore a little common atom being arranged just) that has.At last, throw out represents that a kind of solvent can insert the more weak particulate collective of connection therebetween.
Now will illustrate in greater detail method of the present invention by the description of being done with reference to the accompanying drawings, wherein:
-Fig. 1 is that the thickness " e " (representing with μ m) that adopts the inventive method to prepare the YSZ layer compares r with suspension mVariation diagram;
The apparent viscosity (representing with CP) that-Fig. 2 provides suspension B is with than r mVariation;
-Fig. 3 adopts content of powder TP (%) variation diagram of the thickness " e " (representing with μ m) of the inventive method deposition YSZ layer with suspension B.
(in the step a), prepare powder dispersion in the dispersion medium that contains moisture or organic dispersion solvent, it is dried powder preferably, and promptly its water-content is low, for example is lower than 3 quality % in first step of the inventive method.
In this liquid medium, realize this powder is separated into single particulate by dispersion agent.Therefore obtain the dispersion A or the elementary suspension of described powder in containing the described liquid medium of solvent.
The main application that the present invention relates to is to use the ionogen of the layer of preparation as " SOFC " types of fuel cells, and therefore a kind of oxide powder that is particularly suitable for these purposes is a kind of
Figure G200480016763XD00071
Company with trade(brand)name T-Z8Y sell have cubic crystal structure with the stable Zirconium oxide powder (ZrO of yttrium 2-8%Y 2O 3).
Powder T-Z8Y constitutes by being similar to the single particulate of spheric, and its spherical diameter is 100-200nm, and they are gathered into the more or less spheric agglomerate of the about 30-40 μ of diameter m.Therefore a kind of like this powder of special use describes below, and certainly, this explanation can extend to has same composition, but has in the powder that adopts the prepared different shape of gentle chemical reaction.
Similarly, can expand to any other metal oxide, simple oxide or mixed oxide to the explanation of this method below, or in the mixture of simple or mixed oxide.
For example, the YSZ powder is dispersed in the liquid medium that contains dispersion solvent and dispersion agent, but according to the present invention, opposite with " mud (barbotine) " of doctor-blade casting process, it is plasticizer-containing neither, does not also contain tackiness agent.
In fact, the inventor proves that it is uneven using the prepared layer of suspension that does not contain dispersion agent.Therefore, adding dispersion agent is necessary for powder being dispersed in this suspension better.
Select dispersion agent to form relevant simultaneously with solvent with treating dispersion oxide.This selection is difficult because up to now also without any with regard to dispersion agent with medium like the dispersion category-A in carried out correlative study.
This dispersion agent generally is selected from normally used different ions or nonionogenic tenside when preparation mud.
The commodity phosphoric acid ester that obvious CECA S.A. company sells P312 is particularly suitable for especially the YSZ powder, and for example above-mentioned T-Z8Y powder is dispersed in the solvent of being made up of ethanol and methylethylketone azeotropic mixture (EtOH-MEK) especially.Therefore in fact, during calcining step, after agglomerate split into single particulate, this dispersion agent combined steric effect and electrostatic interaction, and two kinds of effects all stop and make the powder reagglomeration together.
Prepare the employed dispersion solvent of dispersion in step a) and can also be selected from water and organic solvent, for example ketone, aliphatic alcohol class, other organic solvent and composition thereof.
But, confirmed specially suitable solvent by ethanol and methylethylketone azeotropic mixture (with volume ratio: 60-40) constitute.
For example, when using above-mentioned PE-312 as dispersion agent, this solvent can access agglomerate-free stable commodity powder T-Z8Y suspension.The high degree of dispersion powder that obtains according to the present invention shows and can be added to very a large amount of powder (promptly about 75%) in the dispersion solvent, keeps the fluidic rheological charactristics simultaneously.
In dispersion A, the content of metal oxide powder generally is 1-80 quality %, preferably 20-60 quality %.
In powder weight, the mass content of dispersion agent generally is 0.1-10%, preferably 2-3% in dispersion A.
For example, adopt the ultrasonic agitation several minutes, can obtain the dispersion of powder in dispersion A as 10 minutes.
According to an essential characteristic of the present invention, add the solution of at least a polymkeric substance in solvent toward dispersion A.
At this moment these polymer chains make whole dispersed powders flocculations, form a kind of flocculation net that contains these polymer chains, powder, and it can also contain this dispersion agent.
When not adding this polymers soln, even in the presence of dispersion agent, the also film that can not evenly be covered by this suspension, at this moment this suspension be to stick on the base material considerably lessly.At this moment this sedimentary film mainly is made of solvent.After annealing (recuit), the film that obtains is extremely thin, and its thickness cover seldom, and thickness is very inhomogeneous less than micron.
In the process of step b), add the solution of at least a polymkeric substance in solvent of dispersion A to, contain and be selected from water or different organic solvents, for example the solvent of alcohols or aliphatic acids or ketone.Preferred solvent is the solvent of low surface tension, so they can make base material have very high wettability.A kind of preferred solvent is an acetate.
This or these polymkeric substance preferably are selected from poly-(aliphatic ester), and other organic polymer also can be suitable.
Other preferred polymers is the polymkeric substance that can obtain with following polymerizing agent: vulkacit H (HMTA) and Acetyl Acetone (ACAC), their ratio is preferably equimolar.
In heating, for example under temperature 50-80 ℃, in appropriate acidic medium, for example in acetic acid medium, realize the polyreaction of organic chain by " hydrolysis " reaction of HMTA and ACAC.
In order to obtain more closely knit oxide skin after calcining, this polymers soln can also contain the metallic element identical with the dispersion oxide powder.
For this reason, at this moment can be the salt of these metallic elements, for example nitrate, carbonate add concentration to and are generally 0.01-5mol.L -1Polymers soln in.
Can control the extent of reaction of HMTA and ACAC polyreaction.The polymerizing agent concentration of this solution generally is 0.01-10mol.L -1, 0.5-1mol.L preferably -1
Polymer solution viscosity according to above-mentioned parameter, concentration and the progress monitoring of polymerizing agent polyreaction generally is 1-1000mPa.s, preferably 20-100mPa.s.
According to mass ratio r mThe ratio of (colloidal sol quality/dispersion A solution quality) expression is added to the solution or the colloidal sol that contain this polymkeric substance among the dispersion A, and this is than generally being 0.01-3, preferably 0.1-0.6, more preferably 0.1-0.5.
After adding this polymers soln toward dispersion A, can carry out homogenizing, obtain suspension B like this by simple agitation.
The adding mode of suspension component also constitutes a key character of the inventive method.In fact, confirm that different components interpolation order has extremely important influence to the homogeneity of resultant suspension B with to the dispersion state of powder in this suspension.
Therefore, two kinds of feed way are compared, in first kind of feed way, prepare first kind of suspension, wherein oxide powder is added in dispersion solvent/polymer solution-collosol intermixture, and in second kind of feed way according to the present invention, prepares second kind of suspension, wherein before adding polymers soln-colloidal sol, oxide powder is dispersed in the dispersion solvent in advance.
Tested the not r on year-on-year basis of interpolation solution-colloidal sol quality and dispersion solvent m(0.05,0.25 and 0.5) (r m=m Sol/ m The dispersion solvent) two kinds of feed way.
Therefore, for first kind of dispersing mode, colloidal sol and dispersion solvent are at first according to the ratio (r that determines m) mix.Before adding this powder, in this mixture, add dispersion agent.
For second kind of dispersing mode, dispersion agent just mixes with the dispersion solvent, adds this powder then.This suspension is used ultrasonic stirring 10 minutes.At last, according to the ratio (r that determines m) add this colloidal sol.Just carry out homogenizing by stirring this suspension.
The dry extract that adopts MEB to analyze (scanning electronic microscope) suspension characterizes the dispersion state of this powder.By the resulting Photomicrograph of different suspension that extracts according to first kind of feed way preparation all is identical, no matter it compares r mHow, therefore, just contrast r m=0.25 characteristic Photomicrograph is interested.
On the contrary, by according to the resulting Photomicrograph of suspension dry extract of second kind of feed way preparation for r on year-on-year basis not mHas different outward appearances.
These Photomicrographs comparison shows that, the dispersity of the suspension that second kind of feed way can reach is higher than the dispersity that first kind of feed way reaches.
In fact, the size from the suspension agglomerate of first kind of feed way is 20-50 μ m.Can reach a conclusion, as if in this case, the dispersion solvent is without any favourable effect.
On the contrary, no matter it compares r mHow, from the size of the suspension agglomerate of second kind of feed way of the present invention less than 20 μ m.Under all these situations, seeming the major portion of this powder disperses.
The suspension dispersion state of these two kinds of feed way relatively is presented between colloidal sol and the dispersion agent responds.As if allowed colloidal sol contact with dispersion agent before adding powder in fact makes the effect of dispersion agent bury in oblivion.Therefore, necessary is that powder should contact in a kind of appropriate solvent with dispersion agent before adding the colloidal sol polymer chain.
This base material can be any character, but relates in general to a kind of hard substrate.
It for example can be selected from uses metal base material, as the base material made from steel, silicon or aluminium; Be selected from the base material made of pottery, for example with aluminum oxide or contain the yttrium zirconium white or the base material made of doped zirconia not; Be selected from the base material made from glass, and be selected from the composite base material that constitutes with two or more these class materials.
Preferred substrates in " SOFC " range of application is the base material made from porous Ni-YSZ sintering metal, and it for example constitutes anode, as SOFC types of fuel cells anode.
The base material that the present invention uses was not handled before the suspension deposition, and this processing is polishing, thin film deposition etc., and this here is one of them advantage of the inventive method.
This base material can be a porous or fully closely knit.Under latter event, particularly a kind of refractory oxide base material.
At this base material is under the situation of porous substrate, and its open form and/or closed porosity for example can be up to by volumes 50%.This here is another advantage of the inventive method, promptly can obtain the splendid uniform oxide again of quality layer on this two classes base material.As closely knit base material, for example enumerate the YSZ polycrystalline substrate.As porous substrate, enumerate above-mentioned Ni-YSZ sintering metal.
Can also reach control thickness by changing from the speed (step 2 of submergence-removing method) of suspension b taking-up base material.This speed generally can be 0.1-100cm.min -1, 1-10cm.min preferably -1In following these experiments, take-off speed is constant, stuck-at-.4cm.min -1
At first, on the closely knit base material of YSZ, carry out the deposition of layer.
At first proved the above-mentioned r that compares mResulting final oxide layer performance there is significant effects.For the relative quantity of studying colloidal sol and dispersion solvent single-mindedly to influence from the layer form of dispersion, synthesized r mDifference, and these layers that other synthetic parameters remains unchanged for example compare r for all m, content of powder all keeps equaling 50%.From the layer form of suspension relate to that its thickness, base material cover, the existence of agglomerate, density etc., can adopt its form of scanning electron microscope analysis.
These Photomicrographs show, no matter it compares r mHow, the film that obtains all is continuously uniformly, and the ratio r in these suspension mIncrease highly more, the crackle number of laminar surface is also just many more.This reason preferably generally limits r just mBe 0.6.
When relating to layer thickness, these Photomicrographs show when content of powder is constant in keeping suspension, the ratio r of control suspension mCan access the very wide layer of variation in thickness scope: compare r m=0.05 o'clock, layer thickness reached about 80 μ m, and compares r m=0.5 o'clock, layer thickness only reached 7-8 μ m.Therefore than r mLayer thickness there is very intense influence.Fig. 1 has represented the ratio r of layer thickness (in μ m) with suspension m(0≤r m≤ 0.6) variation.
Fig. 1 has proved that the YSZ layer thickness is with than r mAnd asymptotic line reduces.But, for value r m=0, this is corresponding to the suspension that does not have polymkeric substance, and these layers are uneven, their thickness extremely thin (thickness is micron approximately), and this fact shows the importance of adding polymer sol according to the present invention.
Relate in the layer density of calcining after 2 hours under 1000 ℃, it is not too closely knit observing the thinnest layer by these layers Photomicrograph.
These the thinnest layers are from the highest r mThe layer of suspension, promptly contain the suspension of maximum polymer chain.Reach a conclusion thus, the main branch decorrelation with the suspension polymer chain of porosity has nothing to do with the dispersion solvent.
These can draw by the front, and the amount of adding the polymers soln of suspension to by control can be controlled at the layer thickness of preparation in the very wide scope, and their density is controlled in the narrower scope.In fact, compare r mTo the rheology of suspension, therefore layer thickness all there is very intense influence.
To compare r from difference mThe layer thickness variation of suspension and the apparent viscosity of these suspension change and associate.In fact, adopt the submergence-removing method that is utilized, know that very the viscosity of suspension also applies some influence to thin layer form prepared according to the methods of the invention.The apparent viscosity η (representing with mPa.s) that Fig. 2 has provided suspension B is with than r mVariation.
The viscosity that does not contain the suspension of colloidal sol is low-down, is lower than 5mPa.s.Add colloidal sol in the suspension and the unexpected increase of apparent viscosity at first can occur, its apparent viscosity is along with than r then mReduce with the asymptotic line function.
Suspension viscosity is with than r mVariation and layer thickness therefore have very big similarity with the variation of this same ratio.In fact, all observe the phenomenon that reduces with the asymptotic line function in both cases.
In addition, in order to explain that suspension viscosity is with than r mVariation, once studied the rheology of these suspension, simultaneously for same purpose, also to the carrying out of these suspension settling test.
The sedimentation of carrying out studies show that, adds colloidal sol toward these suspension and can not cause powder part reagglomeration, and can cause powder and solvent flocculation.In addition, very limpid owing in the solvent of upper strata, do not have powder fully in the sedimentation front, and also be so in settled whole process, helping proves whole powder particle flocculations, does not agglomerate into variable-sized entity.In fact, just cause dust agglomeration, then can not explain to form very definite sedimentation front portion at once, unless under very uniform agglomeration situation if add colloidal sol.Therefore, perhaps when colloidal sol was added to these suspension, flocculation had taken place in all powder in these suspension.
In addition, in these suspension, the volume of sediment is along with than r mProved in throw out and solvent that and increase for example EtOH-MEK compares and mainly has colloidal sol, therefore perhaps polymer chain participates in forming throw out.We feel the existence of the contiguous network that is made of powder and polymer chain.Therefore so as if under action of gravity, whole just this network sedimentation gets sediment to the end.Yet, compare r mHigh more, chain quantity is also high more with the ratio of the solia particle quantity that participates in network.Therefore observe along with than r mIncrease, the density of sediment then reduces.
It is worthy of note very much, come from the network structure tightness that constitutes by colloidal sol polymer chain and powder particle very for certain by the such possibility of some suspension deposition of thick films.Show like this in the suspension B that the inventive method is used and between metal oxide powder and colloidal sol polymkeric substance, produced real synergy.
In addition, a kind of like this network of formation has been explained to increase and has been compared r mThe time the resultant layer density reason that reduces.In fact, after drying, this settling can be likened to the thin layer of a this network.At this moment sure is, the porosity of final oxide layer is because due to the colloidal sol polymer chain decomposes during calcining step.Therefore for high ratio r m, the network that contains a large amount of colloidal sols obtains porous layer after calcining.
Yet, as if also may between dispersion agent and colloidal sol chemical reaction take place in addition.In fact, this reactive moieties explained according to the operating method opposite with the present invention, the inefficient reason of this dispersion agent when before adding powder dispersion agent being added to colloidal sol.
Do not wish to be subjected to the constraint of any theory, the research of these sedimentation experiments, rheology and suspension performance rule can both propose a kind of hypothesis, and the colloidal sol amount is because due to two kinds of phenomenons to the strong influence of the dispersion state of powder in suspension.At first, a kind of is that secondly, network is more or less very soft owing to forming owing to form a kind of network of relation between colloidal sol polymer chain and powder.This back parameter is the function of chain number and the ratio of the powder particle number that constitutes network seemingly.
People see in front, by can reaching the thickness of control prepared layer to being added to the effect of measuring of dispersion A colloidal sol, but also can reach control thickness by other synthetic parameters, the particularly powder content in suspension B that changes suspension.
So use has constant and equals 0.25 ratio r m, also have different content of powder, promptly 20%, 35% and 60% suspension can be prepared the YSZ layer.Adopted scanning electronic microscope that the different layers that obtains is observed, Photomicrograph and the evaluated error 2 μ m by layer section calculate layer thickness again.
Content of powder is lower than at 20% o'clock, and these layers generally do not cover this base material fully.
According to Fig. 3, system develops according to the power law of coefficient about 1.8 layer thickness (representing with μ m) along with content of powder among the suspension B changes.Therefore opposite with the situation from the layer of classical sol-gel method, this differentiation is not the linear function of oxide content in a kind of precursor medium.When carrying out above-mentioned research (with the ratio r of suspension mKey-course thickness), the differentiation of layer thickness is relevant with the differentiation of suspension viscosity.
Adopt submergence coating method (" dipping ") on base material, to deposit this suspension B.The submergence coating method generally comprises five steps.In a first step, base material is immersed in the suspension.After being immersed in whole base material in the suspension, take out its base material with control speed from suspension B, generally speaking this control speed is 0.1-100cm.min according to the present invention -1, 1-10cm.min preferably -1
When this took out step, the competition between gravity, viscosity and the colloidal sol surface tension had determined the recessed meniscus geometrical shape of base material-liquid surface just, and its shape depends on the thickness of deposit film.Secondly, this settling is under gravity and solvent evaporation keying action and attenuation.This latter two steps is emulative, also carries out simultaneously.
Adopt the deposition step of submergence coating (" dipping ") in being suitable for any device of this purpose, equipment, to implement.
In second research, will transfer on the porous substrate the method that closely knit base material is developed, i.e. the Ni-YSZ sintering metal.The deposition test of colloidal sol on such some base materials show, penetrates in the base material hole by wicking action from the colloidal sol of direct sol-gel method.On the other hand, the deposition test that uses suspension to carry out according to the present invention powder that can observe in the suspension does not infiltrate in the hole of base material.Therefore obviously use the easier film that on porous substrate, obtains of suspension.
Illustrated as the front to closely knit base material, at first use variable ratio r mAnd the constant suspension of content of powder uses variable content of powder and compares r second step then mConstant suspension carries out these depositions.Use Ni-YSZ porous substrate result who obtains and the result who uses the closely knit base material of YSZ to obtain directly to compare.
R is compared in use mBe the suspension of the constant content of powder 50% of 0.08-0.5, promptly with research closely knit base material conditions of similarity under carried out first group of experiment.Also taken extremely than r m0.08 and the Photomicrograph of 0.5 o'clock resultant layer.
Realize that the thickness ratio that uses porous substrate to obtain uses much bigger, all r of closely knit base material mBe worth all like this.
In second group of experiment, prepared from than r mConstant (r m=0.25) and the layer of the suspension of content of powder difference (15-50%).
The Photomicrograph that corresponding to content of powder is 35% suspension shows that when this content, this layer begins to occur crackle.
Not only than these bed thickness that obtain on closely knit base material, and its thickness changes also fast with the content of powder in the suspension at these layers that obtain on the porous substrate.This variation can be described with the power law of coefficient about 2.3.
Can draw thus and successfully realize of the transfer of suspension deposition method from closely knit base material to porous substrate.Use closely knit base material certified as us, the layer thickness increase with content of powder in direct ratioly, and with than r mInversely proportional increase.But, the layer thickness that the layer thickness that uses porous substrate to obtain obtains greater than the closely knit base material of use.This phenomenon should be owing to when deposition suspension and the additional phase mutual effect of porous substrate.Therefore when the sedimentary phenomenon of explanation domination, should consider the porosity of base material.In fact, on porous substrate, may no longer directly connect the viscosity of sedimentary thickness and suspension.
Opposite with the band deposition method, method of the present invention can apply the base material of high surface area, i.e. surface-area 1 to tens cm 2And/or complicated geometrical shape, for example tubulose base material or other three-dimensional article.
After suspension B is deposited on base material (step c)), the living layer that drying obtains.
Generally speaking, in room temperature to 150 ℃, preferably carry out this drying under the temperature of room temperature to 50 ℃.Can in stove or in the crystallizing dish that covers, carry out drying under the air freely.Change rate of drying and time according to carrying out exsiccant temperature and atmosphere, this time generally for example be several minutes to a few hours, preferably 1 minute to 10 hours, more preferably about 1 hour.
Confirm that by the Photomicrograph that carries out the exsiccant layer with friction-motion speed the crackle number of laminar surface increases with rate of drying.Drying means also depends on the crackle form.In fact, along with rate of drying reduces, it is not long that these crackles not only become, and less opens but also become.By these experiments can think drying step for from suspension the layer be full of cracks be decisive step.Therefore, preferably, carry out drying under envrionment temperature and controlled atmosphere, be about 1 hour its time of drying.
After the drying, the living drying layer that obtains is annealed, and calcining at high temperature forms last oxide skin.The temperature that adopts in this step should be higher than the temperature of all organic compound in this suspension.Therefore calcining temperature generally is 200 ℃ to 1800 ℃, and preferably 400-1800 ℃, more preferably 1000 ℃-1400 ℃, this calcining temperature keeps, and the application time generally is several seconds, for example 2 seconds to several hours, and preferably 1-10 hour.
Begin to reach this calcining temperature by room temperature, observing heat-up rate simultaneously generally is from 0.1 to 100 ℃. minute -1, preferably from 1 to 10 ℃. minute -1
Under the situation of the T-Z8Y powder of face description before use, for deposition one deck YZS on a kind of base material, for example it is the Ni-YSZ sintering metal, this powder is 1000 ℃ of preparations down, use this powdered preparation, under this temperature, carry out these layers of annealed simultaneously and can be qualitative be " lifes " layer.
Once proved that the porous substrate of Ni-YSZ sintering metal class can apply 1300 ℃ of temperature, can not change their porosity equally.Therefore, the YSZ layer that is deposited on this base material should be able to be 1300 ℃ of following calcination processing of temperature several hours, for example 2 hours.
Also may be total to-sintering during last calcining step, i.e. sintering layers of oxides of metallic elements and base material the time.When seeking on a kind of porous substrate dense layer of preparation, dielectric substrate for example, as on a kind of porous YSZ base material, Ni-YSZ anode for example, a kind of so common-the sintering particularly advantageous that may seem.Porous ionogen oxidation thing thin layer and base material altogether-when sintering is enforceable, preferably these two kinds of elements have close sintering temperature and approaching thermal expansivity, generally can be at temperature 800-1500 ℃, for example carry out agglomerating anode and electrolytical material under 1200 ℃, for example being respectively Ni-YSZ sintering metal and YSZ, just in time is this situation.
As nonrestrictive illustrative embodiment the present invention is described referring now to following.
Embodiment 1
In this embodiment, contain yttrium zirconium white thin layer at a kind of preparation one deck that contains on the closely knit base material of yttrium zirconium white.
A) preparation contains yttrium Zirconium oxide powder suspension
Preparation 100ml alcohol solvent (EtOH) and methylethylketone (MEK) mixture, it contains 60mlEtOH and 40ml MEK.
Get this mixture of 50g.
Then, add the 125mg dispersion agent toward mixture: P312 commodity phosphoric acid ester.At this moment this dispersion agent dissolves, and its solution carries out homogenizing.Add 50g Tosoh T-8YSZ commodity toward this solution and contain the yttrium Zirconium oxide powder.By ultrasonic wave this powder was disperseed 5 minutes.Therefore obtain " elementary-suspension " A uniformly.
B) preparation polymer sol
According to etc. mol ratio Acetyl Acetone (Acac) and vulkacit H (HMTA) are dissolved in the acetate.The Acac of this solution and HMTA concentration are 0.625M.
Use hot-plate that this solution is heated to about 80 ℃ of temperature.This step prolongs up to the sticky polymers colloidal sol that obtains the about 60mPa.s of a kind of viscosity.
C) preparation is used for sedimentary suspension
Add 10g in the 50g dispersion A at b) polymer sol of preparation.The polymer slurry that obtains carries out homogenizing.
D) prepared layer
Contain in the suspension that the zirconic closely knit base material of yttrium is immersed in step c) preparation, a kind of then with speed 1.4cm.min -1Take out.This layer at room temperature carries out drying, and is dry under air then.This layer is calcined under 1300 ℃ then.
So, obtain the about 40 microns dense layer of thickness.
Embodiment 2
In this embodiment, preparation contains yttrium zirconium white thin layer on a kind of porous substrate.
Operating method is identical with embodiment's 1, only is to use a kind of Ni-YSZ porous substrate of 200nm to 5 micron of bore dia.
Obtain the about 100 microns dense layer of thickness.
Embodiment 1 is to adopt its thickness of scanning electron microscopy measurement with embodiment 2.Two prepared layers of embodiment are uniformly on thickness, also do not have crackle.

Claims (52)

1. the preparation method of layers of oxides of metallic elements on base material, wherein carry out following sequential step:
A) the metallic element oxide powder is dispersed in the liquid medium that contains dispersion solvent and dispersion agent, described liquid medium is plasticizer-containing neither, do not contain tackiness agent yet, obtain the dispersion A of described metallic element oxide powder in described liquid medium like this;
B) solution of at least a polymkeric substance in solvent is added among the described dispersion A, obtains suspension B like this;
C) adopt submergence-taking-up coating method on base material, to deposit suspension B, obtain giving birth to layer like this;
D) layer of giving birth to that obtains in the step c) carries out drying;
E) drying layer that obtains in the step d) is calcined.
2. method according to claim 1, wherein the thickness of the layers of oxides of metallic elements that is obtained by step e) is 1-100 μ m.
3. method according to claim 2, wherein the thickness of the layers of oxides of metallic elements that is obtained by step e) is 1 μ m-10 μ m.
4. the described method of each claim in requiring according to aforesaid right, wherein the metallic element oxide compound is selected from the mixed oxide of multiple element in the simple oxide, these metallic elements of transition element and lanthanon and the mixture of these simple oxides and mixed oxide.
5. according to the described method of each claim among the claim 1-3, wherein the metallic element oxide compound be have cube or the tetragonal system structure contain the yttrium zirconium white.
6. according to the described method of each claim among the claim 1-3, wherein the dispersion solvent is selected from water, ketone, aliphatic alcohol class and composition thereof.
7. method according to claim 3, wherein the dispersion solvent is ethanol/methylethylketone azeotropic mixture.
8. according to the described method of each claim among the claim 1-3, wherein the content of metallic element oxide powder is 1-80 quality % in dispersion A.
9. method according to claim 8, wherein the content of metallic element oxide powder is 20-60 quality % in dispersion A.
10. method according to claim 9, wherein the content of metallic element oxide powder is 30-50 quality % in dispersion A.
11. method according to claim 10, wherein the content of metallic element oxide powder is 30-40 quality % in dispersion A.
12. according to the described method of each claim among the claim 1-3, the size of wherein this metal oxide powder particulate is 5nm to 5 μ m.
13. method according to claim 12, the size of wherein this metal oxide powder particulate is 100-300nm.
14. method according to claim 12, the size of wherein this metal oxide powder particulate is 50-300nm.
15. according to the described method of each claim among the claim 1-3, wherein this dispersion agent is selected from ionic surface active agent and nonionogenic tenside.
16. method according to claim 15, wherein this dispersion agent is a phosphoric acid ester.
17. method according to claim 15, wherein dispersion agent is SA company sells The P312 phosphoric acid ester.
18. according to the described method of each claim among the claim 1-3, wherein the mass content of dispersion agent is 0.1-10 quality % in the metallic element oxide compound dry powder quality that adds in dispersion A.
19. method according to claim 18, wherein the mass content of dispersion agent is 2-3% in the metallic element oxide compound dry powder quality that adds in dispersion A.
20. according to the described method of each claim among the claim 1-3, wherein this polymkeric substance is selected from poly-aliphatic ester.
21. according to the described method of each claim among the claim 1-3, wherein this polymkeric substance is to give birth to medium in acid, reacts resulting polymkeric substance by vulkacit H and Acetyl Acetone.
22. method according to claim 21, wherein said acidic medium is an acetic acid medium.
23. according to the described method of each claim among the claim 1-3, wherein the polymers soln of at least a step b) also contains the metallic element same with oxide powder.
24. according to the described method of each claim among the claim 1-3, wherein the viscosity of the solution of step b) is 5mPa.s to 1000mPa.s.
25. method according to claim 24, wherein the viscosity of the solution of step b) is 20-100mPa.s.
26. according to the described method of each claim among the claim 1-3, wherein in step b), according to mass ratio r with polymers soln quality and dispersion A quality m0.01-3 the ratio of expression is added this polymers soln among the dispersion A to.
27. method according to claim 26, wherein said mass ratio r mBe 0.1-0.6.
28. method according to claim 27, wherein said mass ratio r mBe 0.1-0.5.
29. according to the described method of each claim among the claim 1-3, wherein step c) adopts submergence-taking-up coating method to comprise the step of taking out base material from suspension B, its control speed is 0.1-100cm.min -1
30. method according to claim 29, its control speed is 1-10cm.min -1
31., wherein under room temperature to 150 ℃ temperature, carry out this drying according to the described method of each claim among the claim 1-3.
32. method according to claim 31 is wherein carried out this drying under the temperature of room temperature to 50 ℃.
33. method according to claim 31, wherein be 1 minute to 10 hours time of drying.
34. method according to claim 33, wherein be about 1 hour time of drying.
35., wherein under calcining temperature 200-1800 ℃, carry out the calcining of step e) according to the described method of each claim among the claim 1-3.
36. method according to claim 35 is wherein carried out the calcining of step e) under calcining temperature 400-1800 ℃.
37. method according to claim 36 is wherein carried out the calcining of step e) under calcining temperature 1000-1400 ℃.
38. method according to claim 35 is wherein with 0.1 to 100 ℃ of heat-up rate. minute -1Reach this calcining temperature by room temperature.
39. according to the described method of claim 38, wherein with from 1 to 10 ℃ of heat-up rate. minute -1Reach this calcining temperature by room temperature.
40. method according to claim 35, wherein calcining temperature kept from several seconds to several hours.
41. according to the described method of claim 40, wherein calcining temperature kept 2 seconds to several hours.
42. according to the described method of claim 41, wherein calcining temperature kept 1-10 hour.
43. according to the described method of each claim among the claim 1-3, wherein in step e), sintering or altogether when carrying out layers of oxides of metallic elements and base material-sintering.
44. according to the described method of each claim among the claim 1-3, wherein this base material is very closely knit base material.
45. according to the described method of claim 44, wherein this base material is the refractory oxide base material.
46. according to the described method of each claim among the claim 1-3, wherein this base material is the blunt porous substrate to by volume 50% of open form and/or closed hole.
47. according to the described method of each claim among the claim 1-3, wherein base material is selected from and uses metal base material; Be selected from the base material made from pottery; Be selected from the base material made from glass, and be selected from the composite base material that constitutes with two or more these class materials.
48. according to the described method of claim 47, wherein said metal base material is the base material made from steel, silicon or aluminium.
49., wherein saidly be with aluminum oxide or contain the yttrium zirconium white or the base material made of doped zirconia not with the base material made of pottery according to the described method of claim 47.
50. according to the described method of claim 47, wherein this base material is the base material made from porous Ni-YSZ sintering metal.
51. according to the described method of claim 50, wherein said base material constitutes anode.
52. according to the described method of claim 51, wherein said anode is the anode of SOFC types of fuel cells.
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